Systems and Methods for Remanufacturing Imaging Components

ABSTRACT

A drive gear for a generally cylindrical imaging component. The drive gear includes a body for engaging the generally cylindrical imaging component; a cylindrical shaft attached to the body, the cylindrical shaft having an end surface; and lobes extending longitudinally outward from the end surface.

This application is a continuation of U.S. application Ser. No.14/532,395 filed Nov. 4, 2014, which is a continuation of U.S.application Ser. No. 13/444,511 filed on Apr. 11, 2012, which issued asU.S. Pat. No. 8,879,959, which is a continuation of U.S. applicationSer. No. 13/283,684 filed on Oct. 28, 2011, which issued as U.S. Pat.No. 8,538,295, which is a continuation of U.S. application Ser. No.12/902,625 filed on Oct. 12, 2010, which issued as U.S. Pat. No.8,073,364, which is a continuation of U.S. application Ser. No.11/825,262 filed on Jul. 5, 2007, which issued as U.S. Pat. No.7,813,676, all of which are incorporated by reference herein in itsentirety.

BACKGROUND

The present invention generally relates to manufacturing,remanufacturing or repairing replaceable imaging components, and moreparticularly to apparatus and techniques for providing a drive gear fora drum or roller, such as an organic photo conductor (OPC) drum, forexample, of a replaceable imaging cartridge adapted for holding markingmaterial, such as toner.

In the imaging industry, there is a growing market for the remanufactureand refurbishing of various types of replaceable imaging cartridges suchas toner cartridges, drum cartridges, inkjet cartridges, and the like.These imaging cartridges are used in imaging devices such as laserprinters, xerographic copiers, inkjet printers, facsimile machines andthe like, for example. Imaging cartridges, once spent, are unusable fortheir originally intended purpose. Without a refurbishing process thesecartridges would simply be discarded, even though the cartridge itselfmay still have potential life. As a result, techniques have beendeveloped specifically to address this issue. These processes mayentail, for example, the disassembly of the various structures of thecartridge, replacing toner or ink, cleaning, adjusting or replacing anyworn components and reassembling the imaging cartridge.

Laser printer toner cartridges are typically composed of two portions.One of these sections is the waste bin assembly which houses the OPCdrum. The OPC may include a drive gear which engages with a printerdrive member. During the remanufacturing of a laser printer tonercartridge, the OPC drum may need to be replaced due to the wear ordamage of the OPC drum. The replacement OPC drum may include areplacement drive gear, or gear, attached to one end of the replacementOPC drum. The present invention provides for an improved replacementdrive gear.

SUMMARY

In one aspect of the present invention, a drive gear for a generallycylindrical imaging component includes a body for engaging the generallycylindrical imaging component; a cylindrical shaft attached to the body,the cylindrical shaft having an end surface; and three prongs extendinglongitudinally outward from the end surface.

In another aspect of the present invention, an imaging apparatusassembly includes a drive mechanism including a helical recess; and adrive gear including a body for engaging a generally cylindrical imagingcomponent; a cylindrical shaft attached to the body, the cylindricalshaft having an end surface; and three prongs extending longitudinallyoutward from the end surface and engaging the helical recess.

In another aspect of the present invention, an imaging apparatusassembly includes a generally cylindrical imaging component; and a drivegear including a body engaging a generally cylindrical imagingcomponent; a cylindrical shaft attached to the body, the cylindricalshaft having an end surface; and three prongs extending longitudinallyoutward from the end surface.

A more complete understanding of the present invention, as well asfurther features and advantages of the invention, will be apparent fromthe following detailed description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of a prior art drive mechanism;

FIGS. 2-17 show perspective views of multiple embodiments of a drivegear in accordance with the present invention; and

FIG. 18 shows a drive gear and OPC drum in accordance with the presentinvention.

DETAILED DESCRIPTION

The following detailed description of preferred embodiments refers tothe accompanying drawings which illustrate specific embodiments of theinvention. In the discussion that follows, specific systems andtechniques for providing a drive gear for a drum or roller, such as anorganic photo conductor (OPC) drum, for example, of a replaceableimaging cartridge adapted for holding marking material, are disclosed.Other embodiments having different structures and operations for therepair, remanufacture and operation of other types of replaceableimaging components and for various types of imaging devices, such aslaser printers, inkjet printers, copiers, facsimile machines and thelike, do not depart from the scope of the present invention.

FIG. 1 shows a prior art drive mechanism 100. The drive mechanism 100may include a body 102 having a raised section 104. A helical recess 106may be formed in the raised section 104. The raised section 104 mayinclude an outer cylindrical surface 104 a. In operation, the drivemechanism 100 is part of a printer and engages a gear (not shown) havinga shaped helical extrusion on an imaging cartridge, and causes the gearwith the helical extrusion to rotate. Further details of such a priorart drive mechanism 100 and gear are disclosed in U.S. Pat. No.6,400,914 which is incorporated by reference herein in its entirety.

FIG. 2 shows a drive gear 200 in accordance with the present invention.One end of the drive gear 200 is adapted to be attached to a hollowroller or generally cylindrical imaging component, such as an OPC drum.The other end of the drive gear 200 is adapted to engage the helicalrecess 106 of the drive mechanism 100 of a printer. The drive gear 200includes a body 202 for engaging the generally cylindrical imagingcomponent and a cylindrical shaft 204 attached to the body 202. Thecylindrical shaft 204 has an end surface 206. Three prongs 208 extendlongitudinally outward from the end surface 206 and are shaped to engagethe helical recess 106 of the drive mechanism 100. Each of the threeprongs 208 may be generally triangular in shape with one vertex 208 a ofeach triangular shaped prong 208 being generally rounded.

When the user closes a door of the printer, the drive mechanism 100slides onto the cartridge drive gear 200 so that the three drive gearprongs 208 are inserted into the helical recess 106. As the printerdrive mechanism 100 rotates, the three prongs 208 are engaged, and theentire cartridge drive gear 200 rotates, which in turn drives an OPC(not shown) attached to the drive gear 200. In this embodiment, only theOPC is rotated by this drive interface, however this design is notlimited only to this embodiment. The drive gear may include one or moregears which drive the rest of the cartridge components in addition tothe OPC.

FIG. 3 shows a drive gear 300 in accordance with the present invention.One end of the drive gear 300 is adapted to be attached to a hollowroller or generally cylindrical imaging component, such as an OPC drum.The other end of the drive gear 300 is adapted to engage the helicalrecess 106 of the drive mechanism 100 of a printer. The drive gear 300includes a body 302 for engaging the generally cylindrical imagingcomponent and a cylindrical shaft 304 attached to the body 302. Thecylindrical shaft 304 has an end surface 306. Three prongs 308 extendlongitudinally and radially outward from the end surface 306 and areshaped to engage the helical recess 106 of the drive mechanism 100. Eachof the prongs 308 may be generally rectangular in cross section. Bracingmembers 308 a may be disposed between the prongs 308. The drive gear 300may include one or more gears 310 which drive the additional cartridgecomponents.

FIG. 4 shows a drive gear 400 in accordance with the present invention.One end of the drive gear 400 is adapted to be attached to a hollowroller or generally cylindrical imaging component, such as an OPC drum.The other end of the drive gear 400 is adapted to engage the helicalrecess 106 of the drive mechanism 100 of a printer. The drive gear 400includes a body 402 for engaging the generally cylindrical imagingcomponent and a cylindrical shaft 404 attached to the body 402. Thecylindrical shaft 404 has an end surface 406. Three prongs 408 extendlongitudinally and radially outward from the end surface 406 and areshaped to engage the helical recess 106 of the drive mechanism 100. Eachof the prongs 408 may be generally rectangular in cross section. Thedrive gear 400 may include one or more gears 410 which drive theadditional cartridge components.

FIG. 5 shows a drive gear 500 in accordance with the present invention.One end of the drive gear 500 is adapted to be attached to a hollowroller or generally cylindrical imaging component, such as an OPC drum.The other end of the drive gear 500 is adapted to engage the helicalrecess 106 of the drive mechanism 100 of a printer. The drive gear 500includes a body 502 for engaging the generally cylindrical imagingcomponent and a cylindrical shaft 504 attached to the body 502. Thecylindrical shaft 504 has an end surface 506. Three prongs 508 extendlongitudinally outward from the end surface 506 and are shaped to engagethe helical recess 106 of the drive mechanism 100. Each of the prongs508 may be generally circular in cross section and may be inclined at aslight angle to the end surface 506 in a twisted fashion. The drive gear500 may include one or more gears 510 which drive the additionalcartridge components.

FIG. 6 shows a drive gear 600 in accordance with the present invention.One end of the drive gear 600 is adapted to be attached to a hollowroller or generally cylindrical imaging component, such as an OPC drum.The other end of the drive gear 600 is adapted to engage the helicalrecess 106 of the drive mechanism 100 of a printer. The drive gear 600includes a body 602 for engaging the generally cylindrical imagingcomponent and a cylindrical shaft 604 attached to the body 602. Thecylindrical shaft 604 has an end surface 606. Three prongs 608 extendlongitudinally and latitudinally outward from the end surface 606 andare shaped to engage the helical recess 106 of the drive mechanism 100.Each of the prongs 608 may include a longitudinal element 608 a and alatitudinal element 608 b. The drive gear 600 may include one or moregears 610 which drive the additional cartridge components.

FIG. 7 shows a drive gear 700 in accordance with the present invention.One end of the drive gear 700 is adapted to be attached to a hollowroller or generally cylindrical imaging component, such as an OPC drum.The other end of the drive gear 700 is adapted to engage the helicalrecess 106 of the drive mechanism 100 of a printer. The drive gear 700includes a body 702 for engaging the generally cylindrical imagingcomponent and a cylindrical shaft 704 attached to the body 702. Thecylindrical shaft 704 has an end surface 706. A triangular shapedelement 708 extends outward from the end surface 706 and is shaped toengage the helical recess 106 of the drive mechanism 100. The drive gear700 may include one or more gears 710 which drive the additionalcartridge components.

FIG. 8 shows a drive gear 800 in accordance with the present invention.One end of the drive gear 800 is adapted to be attached to a hollowroller or generally cylindrical imaging component, such as an OPC drum.The other end of the drive gear 800 is adapted to engage the helicalrecess 106 of the drive mechanism 100 of a printer. The drive gear 800includes a body 802 for engaging the generally cylindrical imagingcomponent and a cylindrical shaft 804 attached to the body 802. Thecylindrical shaft 804 has an end surface 806. A cam shaped element 808extends outward from the end surface 806 and is shaped to engage thehelical recess 106 of the drive mechanism 100. The drive gear 800 mayinclude one or more gears 810 which drive the additional cartridgecomponents.

FIG. 9 shows a drive gear 900 in accordance with the present invention.One end of the drive gear 900 is adapted to be attached to a hollowroller or generally cylindrical imaging component, such as an OPC drum.The other end of the drive gear 900 is adapted to engage the helicalrecess 106 of the drive mechanism 100 of a printer. The drive gear 900includes a body 902 for engaging the generally cylindrical imagingcomponent and a cylindrical shaft 904 attached to the body 902. Thecylindrical shaft 904 has an end surface 906. A generally triangularshaped element 908 extends and flares outward from the end surface 906and is shaped to engage the helical recess 106 of the drive mechanism100. The drive gear 900 may include one or more gears 910 which drivethe additional cartridge components.

FIG. 10 shows a drive gear 1000 in accordance with the presentinvention. One end of the drive gear 1000 is adapted to be attached to ahollow roller or generally cylindrical imaging component, such as an OPCdrum. The other end of the drive gear 1000 is adapted to engage thehelical recess 106 of the drive mechanism 100 of a printer. The drivegear 1000 includes a body 1002 for engaging the generally cylindricalimaging component and a cylindrical shaft 1004 attached to the body1002. The cylindrical shaft 1004 has an end surface 1006. A six-pointedstar shaped element 1008 extends outward from the end surface 1006 andis shaped to engage the helical recess 106 of the drive mechanism 100.The drive gear 1000 may include one or more gears 1010 which drive theadditional cartridge components.

FIG. 11 shows a drive gear 1100 in accordance with the presentinvention. One end of the drive gear 1100 is adapted to be attached to ahollow roller or generally cylindrical imaging component, such as an OPCdrum. The other end of the drive gear 1100 is adapted to engage thehelical recess 106 of the drive mechanism 100 of a printer. The drivegear 1100 includes a body 1102 for engaging the generally cylindricalimaging component and a cylindrical shaft 1104 attached to the body1102. The cylindrical shaft 1104 has an end surface 1106. An off-centerelement 1108 having two lobes 1108 a extends outward from the endsurface 1106 and is shaped to engage the helical recess 106 of the drivemechanism 100. The drive gear 1100 may include one or more gears 1110which drive the additional cartridge components.

FIG. 12 shows a drive gear 1200 in accordance with the presentinvention. One end of the drive gear 1200 is adapted to be attached to ahollow roller or generally cylindrical imaging component, such as an OPCdrum. The other end of the drive gear 1200 is adapted to engage thehelical recess 106 of the drive mechanism 100 of a printer. The drivegear 1200 includes a body 1202 for engaging the generally cylindricalimaging component and a cylindrical shaft 1204 attached to the body1202. The cylindrical shaft 1204 has an end surface 1206. A tri-lobeelement 1208 flares outward from the end surface 1206 and is shaped toengage the helical recess 106 of the drive mechanism 100. The drive gear1200 may include one or more gears 1210 which drive the additionalcartridge components.

FIG. 13 shows a drive gear 1300 in accordance with the presentinvention. One end of the drive gear 1300 is adapted to be attached to ahollow roller or generally cylindrical imaging component, such as an OPCdrum. The other end of the drive gear 1300 is adapted to engage thehelical recess 106 of the drive mechanism 100 of a printer. The drivegear 1300 includes a body 1302 for engaging the generally cylindricalimaging component and a cylindrical shaft 1304 attached to the body1302. The cylindrical shaft 1304 has an end surface 1306. A tri-lobeelement 1308 flares outward from the end surface 1306 and is shaped toengage the helical recess 106 of the drive mechanism 100. The drive gear1300 may include one or more gears 1310 which drive the additionalcartridge components.

FIG. 14 shows a drive gear 1400 in accordance with the presentinvention. One end of the drive gear 1400 is adapted to be attached to ahollow roller or generally cylindrical imaging component, such as an OPCdrum. The other end of the drive gear 1400 is adapted to engage thehelical recess 106 of the drive mechanism 100 of a printer. The drivegear 1400 includes a body 1402 for engaging the generally cylindricalimaging component and a cylindrical shaft 1404 attached to the body1402. The cylindrical shaft 1404 has an end surface 1406. A tri-lobeelement 1408 extends outward from the end surface 1406 and is shaped toengage the helical recess 106 of the drive mechanism 100. As shown inFIG. 14, the tri-lobe element 1408 narrows inwards towards a rotationalaxis of the drive gear 1400 as the tri-lobe element 1408 extends outwardfrom the end surface 1406. The drive gear 1400 may include one or moregears 1410 which drive the additional cartridge components.

FIG. 15 shows a drive gear 1500 in accordance with the presentinvention. One end of the drive gear 1500 is adapted to be attached to ahollow roller or generally cylindrical imaging component, such as an OPCdrum. The other end of the drive gear 1500 is adapted to engage thedrive mechanism 100 of a printer. The drive gear 1500 includes a body1502 for engaging the generally cylindrical imaging component and acylindrical shaft 1504 attached to the body 1502. The cylindrical shaft1504 has an end surface 1506. Three prongs 1508 extend longitudinallyand radially outward from the end surface 1506 and are shaped to gripouter cylindrical surface 104 a of the drive mechanism 100. The drivegear 1500 may include one or more gears 1510 which drive the additionalcartridge components.

FIG. 16 shows a drive gear 1600 in accordance with the presentinvention. One end of the drive gear 1600 is adapted to be attached to ahollow roller or generally cylindrical imaging component, such as an OPCdrum. The other end of the drive gear 1600 is adapted to engage thedrive mechanism 100 of a printer. The drive gear 1600 includes a body1602 for engaging the generally cylindrical imaging component and acylindrical shaft 1604 attached to the body 1602. The cylindrical shaft1604 has an end surface 1606. Three prongs 1608 extend longitudinallyand radially outward from the end surface 1506 and are shaped to gripthe outer cylindrical surface 104 a of the drive mechanism 100. Acylindrical element 1612 extends outward to engage the helical recess106 of the drive mechanism 100. The drive gear 1600 may include one ormore gears 1610 which drive the additional cartridge components.

FIG. 17 shows a drive gear 1700 in accordance with the presentinvention. One end of the drive gear 1700 is adapted to be attached to ahollow roller or generally cylindrical imaging component, such as an OPCdrum. The other end of the drive gear 1700 is adapted to engage thehelical recess 106 of the drive mechanism 100 of a printer. The drivegear 1700 includes a body 1702 for engaging the generally cylindricalimaging component and a cylindrical shaft 1704 attached to the body1702. The cylindrical shaft 1704 has an end surface 1706. A triangularshaped element 1708 extends longitudinally outward from the end surface1706 and is shaped to engage the helical recess 106 of the drivemechanism 100. The element may generally triangular in shape but missingone vertex 1708 a. A cylindrical shaped element 1712 is shaped to engagethe outer cylindrical surface 104 a of the drive mechanism 100. Thedrive gear 1700 may include one or more gears 1710 which drive theadditional cartridge components.

FIG. 18 shows the drive gear 200 attached to an OPC drum 1800 inaccordance with the present invention.

Although specific embodiments have been illustrated and describedherein, those of ordinary skill in the art appreciate that anyarrangement that is calculated to achieve the same purpose may besubstituted for the specific embodiments shown and that the inventionhas other applications in other environments. This application isintended to cover any adaptations or variations of the presentinvention. The following claims are in no way intended to limit thescope of the invention to the specific embodiments described herein.

What is claimed is:
 1. A drive gear for a generally cylindrical imagingcomponent, the drive gear comprising: a body for engaging the generallycylindrical imaging component having a rotational axis; an end surfacemechanically coupled to the body; and a lobed element for engaging arecess, said lobe element extending outward from the end surface, saidlobed element narrowing inward towards the rotational axis as the lobedelement extends outward from the end surface.
 2. The drive gear of claim1 wherein the end surface is mechanically coupled to the body by acylindrical shaft.
 3. The drive gear of claim 1 wherein the lobedelement comprises three lobes.